Protein containing molded food products

ABSTRACT

Novel, edible, pressure molded proteinaceous wafer, waffle, inclusion ingredient, and cookie food products are derived utilizing an engineered batter formulation including proteinaceous materials, water, oils/fats, flavors, and select percentages of carbohydrates. The batter has a specific mass balance ratio that allows the wafers to be consistently manufactured on process equipment that was designed for carbohydrate wafer, waffle, or cookie processing. The novel engineered mass balance-based protein formulation provides a batter that can be pumped, utilizes standard steam port pressure relief systems, and results in a final food product that has marketable organoleptic qualities as a component in fabricated protein bars/snacks, confections, as in inclusion in other foods, or as an independent snack food, frozen breakfast food, cookie, or cone product.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.10/318,950, filed Dec. 13, 2002, which itself claims priority toProvisional patent application 60/340,236, filed Dec. 14, 2001, each ofthe contents of the entirety of which are incorporated by thisreference.

BACKGROUND OF THE INVENTION

Currently, all molded, baked, wafer-waffle-cookie food products are madefrom high carbohydrate/fat/lecithin/water batter formulations, processedon expensive continuous process lines, utilizing molding plate and drumtechnology, including but not limited to large scale commercialequipment from Hebenstreit and Franz Haas. Such specialized processequipment systems have been designed for mixing, pumping, applying(depositing), molding, baking, and processing high carbohydrate-basedbatters and resulting final molded food products includingbars/cones/confections/inclusions/waffles/wafercookies/pizzelles/fortune cookies. High protein batters and resultingfood products cannot be easily processed on this equipment due to thefact that these highly engineered standardized process systems have beendesigned specifically for handling highcarbohydrate/water/fat/oil/lecithin batters having known properties.

SUMMARY OF THE INVENTION

The invention relates generally to a novel engineered mass balancebatter formulation of proteins/carbohydrates to water with a specifiedviscosity range for commercially processable proteinaceous pressuremolded fabricated food products including plain wafers/waffles/cookies,flavored wafers/waffles/cookies, layered wafer bars, enrobed wafer bars,flavored wafer bars, sandwich wafer snacks, proteinaceous inclusioningredients, fabricated wafer inclusion bars/cookies/confections, cremefilled wafer food products, cone products, wafer confections, andpizzelle wafer cookies, Chinese fortune cookies, and high moisturebreakfast waffles.

However, the inventive engineered mass balance formulation ofproteins/fat/lecithin/water/flavor systems, and carbohydrates, allowshigh-protein batters and resulting wafers to be processed on existingprocess equipment, without requiring extensive re-engineering andmodification of the wafer equipment, including new wafer molding platesteam pressure release ports, batter mixing and pumping/piping systems,and batter applicator (depositing) heads.

The novel, edible, proteinaceous batter formulation is engineered for anecessary specific mass balance ratio for consistent manufacturing ofthe pressure molded food products on equipment designed specifically forstandard high carbohydrate formulation batter processing. This inventivemass balance-viscosity controlled batter technology has been engineeredto have process-related properties that are similar or identical tothose of the standard high percentage carbohydrate-based batters andfinal food products, so that they can be processed on the equipment thatis designed for such. It was discovered that the mass balance-controlledviscosity formulation ratio is crucial. Without the massbalance-viscosity ratio, a protein-based batter would significantlyincrease standard steam port pressure, with possible explosionramifications; costly steam port modification of the standard processmolding equipment would have to be undertaken, which would includere-engineering and manually modifying all of the wafer molding platesteam pressure release ports to specifically handle identified steampressure requirements. In addition, the batter mix and pump systemswould need to be modified to handle high batter viscosities, and plateapplicator nozzles for the new batters would have to be modified forhandling the high water, highly viscous batter application.

The novel technology addresses these items, for it is based on utilizinga formulation of proteinaceous materials, with selectdispersant-agglomerated proteinaceous materials in conjunction withfiller proteinaceous materials, or structural case hardeningproteinaceous materials, and/or encapsulated proteinaceous ingredientsand carbohydrates. This formulation is blended and mixed with a specificamount of water, desired sweetener/flavoring agent system, lecithin, andoil/fat, and blended thoroughly until well mixed and possessing a smoothbatter-like property. The specific solids: water mass balance ratio isfrom 1.00:0.500 to 1.00:4.00, not including any fats or lecithin in thebatter. The batter must also possess a viscosity of greater than 100centipoise but less than 25,000 centipoise at 24° C. The specificformulation of proteinaceous material ingredients is designed to bebroad, but allows for the use of combinations of whey protein isolate,modified wheat protein isolate, gluten, soy protein isolate, wheyprotein concentrate, textured wheat protein, instantized whey proteinisolate, instantized whey protein concentrate, milk protein concentrate,milk protein isolate, instantized milk protein isolate, soy proteinconcentrate, instantized soy protein, hydrolized collagen, gelatin,hydrolyzed gelatin, rennet casein, acid casein, egg protein, caseinates,instantized caseinates, single cell proteins, and encapsulated and/ordenatured and/or crosslinked versions of such in calculated ratios.

The formulation of proteins/carbohydrates is mixed with water to meetthe engineered mass balance-viscosity requirements. It is then blendedthoroughly to eliminate particle clumping. Lecithin, sweetener, flavorsystems, and oil/fat are then added to the mixed batter and furtherblended and properly dispersed within the protein matrix. The batter isthen pumped and directly applied to the molding plates or heated drummold. The high temperature plates are then closed upon each other,sandwiching the batter or the heated drum turns. The water in the batteris converted to steam and flashed off through the steam pressure releaseports. The food product is baked to desired moisture content of lessthen 25% but greater than 1%. The resulting final food product is amolded, structurally stable, and possessing a proteinaceous profile ofgreater than 25% dry weight. This molded food product is then optionallyfurther processed into layered wafer creme bars, enrobed wafer cremebars, flavored wafer creme bars, sandwich wafer snacks, cone products,creme filled wafer products, converted into wafer inclusions for otherbars/snacks/confections/foods, a wafer snack food product, a wafercookie product (pizzelle), or a frozen breakfast waffle.

This invention features pressure molded proteinaceouswafers-cookies-waffles with greater than 25% dry weight proteincomposition, the pressure molding process to make such, and allresulting fabricated foods/confections/ingredients made utilizing theproteinaceous molded food items.

The proteinaceous molded foods may be made utilizing a protein blendconsisting of proteinaceous ingredients, water soluble proteinaceousmaterials, and filler proteins, including whey protein isolate, modifiedwheat protein isolate, gluten, soy protein isolate, whey proteinconcentrate, textured wheat protein, textured vegetable protein, singlecell protein, instantized whey protein isolate, instantized whey proteinconcentrate, milk protein concentrate, milk protein isolate, instantizedmilk protein isolate, soy protein concentrate, instantized soy protein,hydrolyzed collagen, gelatin, hydrolyzed gelatin, rennet casein, acidcasein, egg protein, caseinates, instantized caseinates, and/fat and/orlecithin and/or wax and/or carbohydrate encapsulated versions orcrosslinked or denatured versions of such. The proteinaceous ingredientsmay be crosslinked or bridged utilizing chemical and enzymaticcrosslinking and/or bridging agents. These protein ingredients canoptionally be blended with a carbohydrate including flour, starch,modified starch, soluble fiber, insoluble fiber, sugar, carbohydratesyrup, sugar alcohol, and modified flour.

The proteinaceous molded food item may be manufactured utilizing aprotein/carbohydrate batter with a mass balance solids to water ratiobetween 1.00:0.500 to 1.00:4.00, not including the fats or lecithinincluded in the batter. The protein wafers may be manufactured inpressure molding systems, utilizing heated molding plates or drum, withtemperatures less than 500° F., but greater than 100° F. The moldedproteinaceous food item may be manufactured utilizing a protein batterwith a viscosity less than about 25,000 centipoise (cP) but greater than100 centipoise (cP), with the preferred being less than 5,000 cP butgreater than 500 cP. The proteinaceous food products may be utilized tomake flavored wafers, layered wafer bars, enrobed wafer bars, flavoredwafer bars, sandwich wafer snacks, proteinaceous inclusion ingredients,fabricated wafer inclusion bars/cookies/candies, creme filled waferproducts, wafer cone products, wafer confections, wafer cookies, andpizzelle wafer cookies, breakfast waffles, and a Chinese fortunecookie-like product.

DETAILED DESCRIPTION OF THE INVENTION

The following are examples of the invention:

EXAMPLE 1

A batter blend of ingredients including 21% instantized (lecithinagglomerated) whey protein isolate (92% protein), 21% textured wheatprotein (72% protein), 3% lecithin, 1% rice bran oil, 0.2% Sucralose(artificial sweetener), 0.1% vanillin, and 55% water were blended in ahigh speed homogenizing mixer until thoroughly liquefied into abatter-like consistency. The protein batter product was then directlyapplied to a preheated (310° F.) Heibenstreit stainless steel moldedwafer plate. The plates were closed and locked in place, applying directheat to the 2 mm batter sheet. Steam released through the vents and theproduct was cooked, under pressure, for 2.0 minutes. Final protein waferwas durable and low moisture (about 2% moisture).

The solids to water mass balance of the batter is 1.00:1.25 and theviscosity of the batter (no added emulsifying agents, fats, sweeteners)was 1933 cP (±12% torque) @ 23.1° C. as run on a Brookfield DV-II+Viscometer.

Final chemical composition of the pressure molded protein wafer was 78%protein, 5% fat, and 9% carbohydrate.

EXAMPLE 2

A batter blend of ingredients including 99 lbs (26%) instantized(lecithin agglomerated) whey protein isolate (@92% protein), 40 lbs(10.5%) textured wheat protein (@72% protein), 40 lbs wheat flour, 3%lecithin, 1% rice bran oil, 0.2% Sucralose (artificial sweetener), 0.1%vanillin, and 200 lbs (53%) water were blended in a high speed squarevessel mixer until thoroughly liquefied/blended into a batter-likeconsistency. The proteinaceous batter was then pumped through anoverhead stainless steel 2 inch pipe system to the wafer machine andwand applied to preheated (about 210° F.) Haas stainless steel moldedwafer plates. The plates were closed and locked in place, applyingdirect heat to the 2 mm batter sheet. Steam released through the ventsand the product was cooked, under pressure, for 2.0 minutes. Finalprotein wafer was durable and low moisture (about 2% moisture).

The solids to water mass balance of the batter is 1.00:1.12 and theviscosity of the batter (no added emulsifying agents, fats, sweeteners)was 1600 cP (±40.7% torque) @ 24.1° C. as run on a Brookfield DV-II+Viscometer. The chemical composition of the wafer product is 67%protein, 22% carbohydrate, and 6% fat.

EXAMPLE 3

Proteinaceous batter ingredients including 18 parts (18%) instantizedwhey protein isolate, 12 parts (12%) textured wheat protein, 12 parts(12%) soy protein isolate, 3 parts (3%) lecithin, 1 part (1%) rice branoil, 0.2 parts Sucralose (artificial sweetener), 0.1 parts lemon oil,and 53 parts (53%) water were blended in a high speed homogenizing mixeruntil thoroughly liquefied into a smooth batter-like consistency. Theprotein batter product was then directly applied to a preheated (310°F.) Teflon coated pizzelle wafer cookie molding plate system. The plateswere closed and locked in place, applying direct heat to the 2 mm battersheet. Steam released through the vents and the product was cooked,under pressure, for 2.5 minutes. Final high protein molded pizzellewafer cookie was light weight, low moisture (<2%), and possessed acomposition of 78% protein, 7% fat, and 4% carbohydrate.

The solids to water mass balance of the batter is 1.00:1.27 and theviscosity of the batter (no added emulsifying agents, fats, sweeteners)was 2000 cP (±11.5% torque) @ 23.8° C. as run on a Brookfield DV-II+Viscometer.

EXAMPLE 4

A batter blend of ingredients including 99 lbs (26%) instantized(lecithin agglomerated) whey protein isolate (@ 92% protein), 40 lbs(10.5%) textured wheat protein (@72% protein), 40 lbs wheat flour, 3%lecithin, 1% rice bran oil, 0.2% Sucralose (artificial sweetener), 0.1%vanillin, and 200 lbs (53%) water were blended in a high speed squarevessel mixer until thoroughly liquefied/blended into a batter-likeconsistency. The proteinaceous batter was then pumped through anoverhead stainless steel 2 inch pipe system to the wafer machine andwand applied to pre-heated (about 210° F.) Haas stainless steel moldedwafer plates. The plates were closed and locked in place, applyingdirect heat to the 2 mm batter sheet. Steam released through the ventsand the product was cooked, under pressure, for 2.0 minutes. Finalprotein wafer was durable and low moisture (about 2% moisture).

The solids to water mass balance of the batter is 1.00:1.12 and theviscosity of the batter (no added emulsifying agents, fats, sweeteners)was 1600 cP (±40.7% torque) @ 24.1° C. as run on a Brookfield DV-II+Viscometer. The chemical composition of the wafer product is 67%protein, 22% carbohydrate, and 6% fat.

Wafers were then transferred to a layering system where wafers were thentaken individually, and a thin layer of hot protein-fat creme wasapplied to the top of 3 (three). The cremed wafers were then assembled abook format-placing one on top of the other, with the last no-cremewafer going on top, creating a wafer-creme-wafer-creme-wafer-creme-waferproduct. The product was then allowed to cool, and then cut into four1.25″×5″ layered wafer creme protein bars.

EXAMPLE 5

A batter blend of ingredients including 20 parts wheat flour (26%), 10parts (13%) whey protein isolate, 2 parts dried egg white powder (2.5%),and 36 parts (46%) water were blended in a high speed mixer untilthoroughly liquefied into a batter. The protein batter product was thendirectly applied to a preheated (350° F.) Heibenstreit stainless steelmolded wafer plate. The plates were closed and locked in place, applyingdirect heat to the 3 mm batter sheet. Steam released through the ventsand the product was cooked, under pressure, for 2.5 minutes. Finalprotein wafer was durable and low moisture.

Final chemical composition of the pressure molded 5″×7″ proteinaceouswafer was 38% protein, 3% fat, and 56% carbohydrate.

The solids to water mass balance of the batter is 1.00:1.12 and theviscosity of the batter (no added emulsifying agents, fats, sweeteners)was 660 cP (±16.4% torque) @ 24.5° C. as run on a Brookfield DV-II+Viscometer.

EXAMPLE 6

Proteinaceous batter blend of ingredients including 15 parts (14%) wheyprotein isolate, 20 parts (19%) wheat flour, 5 parts (5%) compositeprotein (@ 85% protein), 5 parts (5%) rennet casein, and 60 parts (57%)water were blended in a high speed mixer until thoroughly liquefied intoa batter-like consistency. The proteinaceous batter product was thendirectly applied to a preheated (300° F.) Heibenstreit stainless steelmolded wafer plate. The plates were closed and locked in place, applyingdirect heat to the 3 mm batter sheet. Steam released through the ventsand the product was cooked, under pressure, for approximately 2 minutes.Final protein wafer was durable and low moisture (<2%).

The solids to water mass balance of this batter is 1.00:1.33 and theviscosity of the batter (no added emulsifying agents, fats, sweeteners)was 556 cP (±13.7% torque) @ 24.1° C. as run on a Brookfield DV-II+Viscometer.

Final chemical composition of the pressure molded 5″×7″ protein waferwas 52% protein, 3% fat, and 40% carbohydrate.

EXAMPLE 7

Proteinaceous batter blend of ingredients including 15 parts (14%) wheyprotein isolate, 20 parts (19%) wheat flour, 5 parts (5%) compositeprotein (@ 85% protein), 5 parts (5%) rennet casein, and 60 parts (57%)water were blended in a high speed mixer until thoroughly liquefied intoa batter-like consistency. The proteinaceous batter product was thendirectly applied to a preheated (300° F.) Heibenstreit stainless steelmolded wafer plate. The plates were closed and locked in place, applyingdirect heat to the 3 mm batter sheet. Steam released through the ventsand the product was cooked, under pressure, for approximately 2 minutes.Final protein wafer was durable and low moisture (<2%).

The solids to water mass balance of this batter is 1.00:1.33 and theviscosity of the batter (no added emulsifying agents, fats, sweeteners)was 556 cP (±13.7% torque) @ 24.1° C. as run on a Brookfield DV-II+Viscometer.

Final chemical composition of the pressure molded 5″×7″ protein waferwas 52% protein, 3% fat, and 40% carbohydrate.

4 (four) of the above described wafers were then placed flat down,individually, and a thin layer of hot vanilla flavored protein creme wasapplied to the top of 3 (three). The wafers were then assembled in abook format-placing one on top of the other, with the last no-cremewafer going on top, creating a wafer-creme-wafer-creme-wafer-creme-waferproduct. The product was then allowed to cool, and then cut into four1.25″×7″ protein bars.

EXAMPLE 8

Proteinaceous ingredients including 25% instantized whey proteinisolate, 23% textured wheat protein, 3% lecithin, 1.5% high oleicsafflower oil, 0.2% Sucralose (artificial sweetener), 1% nutmeg spicepowder, 3% cinnamon spice powder, and 51% water were blended in a highspeed mixer until thoroughly liquefied into a batter-like consistency.The protein batter product was then directly applied to a preheated(390° F.) Heibenstreit stainless steel molded wafer plate. The plateswere closed and locked in place, applying direct heat to the 5 mm battersheet. Steam released through the vents and the product was cooked,under pressure, for 3 minutes. Final protein wafer was durable and lowmoisture (<4%).

The solids to water mass balance of this batter is 1.00:1.03 and theviscosity of the batter was 4900 cP (±29.5% torque) @ 24.1° C. as run ona Brookfield DV-II+ Viscometer. Final chemical composition of thepressure molded 5″×7″ protein wafer was 78% protein, 8.5% fat, and 7.5%carbohydrate.

EXAMPLE 9

Proteinaceous batter blend of ingredients including 16.6% whey proteinisolate, 16.6% dried egg white powder, 16.6% wheat flour, and 50% waterwere blended in a high speed mixer until thoroughly liquefied into abatter-like consistency. The protein batter product was then directlyapplied to a preheated (225° F.) Heibenstreit stainless steel moldedwafer plate. The plates were closed and locked in place, applying directheat to the 5 mm batter sheet. Steam released through the vents and theproduct was cooked, under pressure, for 3-4 minutes. Final protein waferwas durable and low moisture.

The solids to water mass balance of this batter is 1.00:1.00 and theviscosity of the batter (no added emulsifying agents, fats, sweeteners)was 2450 cP (±62% torque) @ 25° C. as run on a Brookfield DV-II+Viscometer.

Final chemical composition of the pressure molded 5″×7″ protein waferproduct was 60% protein, 3% fat, and 30% carbohydrate.

EXAMPLE 10

Proteinaceous ingredients including 17% wheat flour, 17% rice flour, 9%acid casein, 2% dried egg white powder and 56% water were blended in ahigh speed mixer until thoroughly liquefied into a batter-likeconsistency. The protein batter product was then directly applied to apreheated (325° F.) Heibenstreit stainless steel molded wafer plate. Theplates were closed and locked in place, applying direct heat to the 5 mmbatter sheet. Steam released through the vents and the product wascooked, under pressure, for 2-3 minutes. Final protein wafer was durableand low moisture (<4%).

The solids to water mass balance of this batter is 1.00:1.26 and theviscosity of the batter (no added emulsifying agents, fats, sweeteners)was 1300 cP (±10.2% torque) @ 25.6° C. as run on a Brookfield DV-II+Viscometer.

Final chemical composition of the pressure molded 5″×7″ protein waferwas 25% protein, 3% fat, and 64% carbohydrate.

EXAMPLE 11

Proteinaceous batter blend of ingredients including 24% whey proteinisolate, 22% textured wheat protein, and 54% water were blended in ahigh speed mixer until thoroughly liquefied into a batter-likeconsistency. The protein batter product was then directly applied to apreheated (375° F.) Heibenstreit stainless steel molded wafer plate. Theplates were closed and locked in place, applying direct heat to the 5 mmbatter sheet. Steam released through the vents and the product wascooked, under pressure, for 3-4 minutes. Final protein wafer was durableand low moisture.

The solids to water mass balance of this batter is 1.00:1.14 and theviscosity of the batter (no added emulsifying agents, fats, sweeteners)was 2600 cP (±15.6% torque) @ 23.1° C. as run on a Brookfield DV-II+Viscometer.

Final chemical composition of the pressure molded 5″×7″ protein waferproduct was 83% protein, 3% fat, and 10% carbohydrate.

The wafers were then placed into a single arm mixer and thoroughlyground into small pieces (for inclusion in other foods) ranging in sizefrom 1 mm×1 mm to 10 mm×20 mm. The wafer pieces, termed inclusions, werethen incorporated into a peanut butter protein creme at a ratio of 1part wafer:2 parts peanut butter protein creme. The combination productwas then thoroughly blended together at a temperature of approximately40-45° C., followed by molding into a bar utilizing a UHMW polymer mold,chilling the molded bar matrix in a temperature controlled unit to 7° C.for set-up, followed by removing bar slab from mold, cutting slab into1.25″×6″ bars, followed by applying a protein based compound chocolatecreme coating.

1. A molded food product comprising: a wheat flour; a first protein; asecond protein, the first protein being different than the secondprotein; and a fat, an oil, or a combination thereof; wherein the moldedfood product is made in a heated drum mold under pressure and at atemperature of at least 212° F. and less than 500° F.
 2. The molded foodproduct of claim 1, wherein: the first protein is soy protein; and thesecond protein is selected from the group consisting of a wheat protein,a whey protein, an egg protein and any combination thereof.
 3. Themolded food product of claim 1, further comprising a compound selectedfrom the group consisting of an artificial sweetener, lecithin, and acombination thereof.
 4. The molded food product of claim 1, the moldedfood product having at least 25% protein by dry weight.
 5. A foodproduct comprising: a wafer comprising: a wheat flour; and at least oneproteinaceous ingredient; a protein containing creme contacting thewafer.
 6. The food product of claim 5, further comprising a coatingenrobed over the food product.
 7. The food product of claim 5, whereinthe coating comprises chocolate.
 8. The food product of claim 5, whereinthe protein containing creme comprises peanut butter.
 9. The foodproduct of claim 5, wherein the at least one proteinaceous ingredient isselected from the group consisting of whey protein isolate, wheatprotein isolate, gluten, soy protein isolate, whey protein concentrate,textured wheat protein, instantized whey protein isolate, milk proteinconcentrate, milk protein isolate, instantized milk protein isolate, soyprotein concentrate, instantized soy protein, hydrolyzed collagen,gelatin, hydrolyzed gelatin, rennet casein, acid casein, egg protein,caseinates, instantized caseinates, and single cell proteins.
 10. Thefood product of claim 5, the wafer further comprising an ingredientselected from the group consisting a starch, a modified starch, asoluble fiber, an insoluble fiber, sugar, a carbohydrate syrup, a sugaralcohol, and a modified flour.
 11. A food product comprising: a wafercomprising: a flour; at least one proteinaceous ingredient; and a fat,an oil, or a combination thereof; the wafer being made in a heated drummold under pressure and at a temperature of at least 212° F. and lessthan 500° F.; a protein containing creme contacting the wafer; and acoating enrobing the food product.
 12. The food product of claim 11,wherein the protein containing layer creme comprises peanut butter. 13.The food product of claim 11, wherein the at least one proteinaceousingredient is selected from the group consisting of wheat proteinisolate, soy protein isolate, whey protein isolate, an egg protein, acaseinate, and any combination thereof.
 14. The food product of claim11, wherein the wafer further comprises an artificial sweetener.
 15. Thefood product of claim 14, wherein the artificial sweetener comprisessucralose.
 16. The food product of claim 11, wherein the wafer furthercomprises lecithin.
 17. A food product comprising: a wafer comprising: aflour; a whey protein isolate; a soy protein isolate; an egg protein; afat, an oil, or a combination thereof; lecithin; and an artificialsweetener; a protein and fat containing layer contacting the wafer; anda coating enrobing the food product.
 18. The food product of claim 17,wherein the artificial sweetener comprises sucralose.
 19. The foodproduct of claim 17, wherein the protein and fat containing layercomprises peanut butter.
 20. The food product of claim 17, wherein thecoating comprises chocolate.